Multi-drive conveyor systems and methods of using same

ABSTRACT

Disclosed is a conveyor system and method for advancing an item relative to a transport axis. The conveyor system includes a conveyor belt and a modular drive assembly having at least one drive module and at least one take-up module. Each drive module and each take-up module has a housing and a pulley assembly positioned within the housing. The respective positions of the housings of the at least one drive module and the at least one take-up module relative to the transport axis are selectively adjustable to modify the conveyor movement pathway. Moreover, the drive module can also include a drive pulley removal apparatus that is detachably secured within the housing for selective removal and replacement of a drive pulley.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of the filing dateof U.S. Provisional Patent Application No. 62/455,826, filed Feb. 7,2017, which is incorporated herein by reference in its entirety.

FIELD

The disclosed invention relates to conveyor systems that can be used onbulk flow belt conveyors and, more particularly, to conveyor systemshaving modular drive assemblies that can be selectively adjustable tomodify the conveyor movement pathway.

BACKGROUND

Current belt conveyors are typically bulky, fixed assemblies that arecustomized for particular end applications. Modification of suchconveyors or replacement of conveyor components typically requiressubstantial or complete dismantling of the conveyor assembly. Forexample, installation and removing of motorized drive componentsrequires “breaking” the conveyor belt, and a change in the overallmovement pathway of the conveyor can only be accomplished by dismantlingthe entire conveyor assembly. Thus, any installation or maintenanceactivity can result in significant operational downtime. Additionally,drive components (e.g., motors, reducers, and belts) of current beltconveyor systems are separately and permanently installed and can onlybe adjusted or replaced by a maintenance worker positioned within thesupport structure of the conveyor. To accomplish the adjustments andreplacements, maintenance workers typically must position themselvesinside the support structure with potentially rotating equipment inorder to gain sufficient access to the portions of the system thatrequire attention. Such conditions can lead to injuries to themaintenance workers.

Thus, there is a need for conveyor systems and methods that address oneor more of the deficiencies of existing conveyor systems. For example,there is a need for conveyor systems that can provide flexible conveyorconfigurations and/or simplify (and improve the safety of) theinstallation and removal of drive components.

SUMMARY

Described herein, in various aspects, is a conveyor system for advancingan item relative to a transport axis. The conveyor system can include aconveyor belt and a modular drive assembly. The modular drive assemblycan include at least one drive module and at least one take-up module.Each drive module can include a housing and a pulley assembly that canbe positioned within the housing. The pulley assembly of each drivemodule can be configured to engage the conveyor belt and drive movementof the conveyor belt along a conveyor movement pathway. Each take-upmodule can include a housing and a pulley assembly that can bepositioned within the housing. The pulley assembly of each take-upmodule can be configured to engage the conveyor belt and provide tensionto the conveyor belt as the conveyor belt moves along the conveyormovement pathway. The respective positions of the housings of the atleast one drive module and the at least one take-up module relative tothe transport axis can be selectively adjustable to modify the conveyormovement pathway.

Also described herein is a drive module for a conveyor system. The drivemodule can include a housing, a pulley assembly, and a drive pulleyremoval apparatus. The pulley assembly can be positioned within thehousing and include a motorized drive pulley. The motorized drive pulleycan have at least one mounting bracket for detachably securing themotorized drive pulley to the housing. The motorized drive pulley ofeach drive module can be selectively removable and replaceable. Thedrive pulley removal apparatus can be detachably secured within thehousing. Following detachment of the motorized drive pulley from thehousing, the drive pulley removal apparatus can be configured to engagethe at least one mounting bracket of the motorized drive pulley andeffect movement of the motorized drive pulley from a stowed positionwithin the housing of the drive module to an accessible position inwhich at least a portion of the motorized drive pulley can be outsidethe housing of the drive module.

Further described herein is a method of driving a conveyor to advance anitem relative to a transport axis. The method can include selectivelypositioning a conveyor drive assembly in a first configuration to definea first conveyor movement pathway. The conveyor drive assembly caninclude a plurality of modules. Each module of the conveyor driveassembly can have a housing and a pulley assembly that can be positionedwithin the housing. The housings of the plurality of modules can beselectively positioned relative to the transport axis to define thefirst conveyor movement pathway. The method can also include positioninga first item on a conveyor belt positioned in engagement with the pulleyassembly of each module of the conveyor drive assembly. The method canalso include driving movement of the conveyor belt relative to the firstconveyor movement pathway. The method can further include disengagingthe conveyor belt from the pulley assembly of at least one module of theconveyor drive assembly. The method can include selectively adjustingthe positioning of the housing of at least one module of the conveyordrive assembly to define a second conveyor movement pathway that isdifferent from the first conveyor movement pathway. The method can alsoinclude positioning the conveyor belt in engagement with the pulleyassemblies of the plurality of modules of the conveyor drive assembly.The method can further include positioning a second item on the conveyorbelt. The method can include driving movement of the conveyor beltrelative to the second conveyor movement pathway.

Still further described herein is a method of driving a conveyor toadvance an item relative to a transport axis. The method can includeselectively positioning a conveyor drive assembly in a firstconfiguration to define a first conveyor movement pathway. The conveyordrive assembly can include a plurality of modules. Each module of theconveyor drive assembly can have a housing and a pulley assembly thatcan be positioned within the housing. The plurality of modules caninclude a drive module. The pulley assembly of the drive module caninclude a motorized drive pulley. The housings of the plurality ofmodules can be selectively positioned relative to the transport axis todefine the first conveyor movement pathway. The method can also includepositioning a conveyor belt in engagement with the pulley assemblies ofthe plurality of modules of the conveyor drive assembly such that theconveyor belt forms a closed loop. The method can further includeselectively removing and replacing the motorized drive pulley of thedrive module without breaking the closed loop formed by the conveyorbelt.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an exemplary configuration of aconveyor system for advancing an item relative to a transport axis asdisclosed herein.

FIG. 2 is a schematic diagram of another exemplary configuration of aconveyor system for advancing an item relative to a transport axis asdisclosed herein.

FIG. 3 is a schematic diagram of another exemplary configuration of aconveyor system for advancing an item relative to a transport axis asdisclosed herein.

FIG. 4 is a schematic diagram of another exemplary configuration of aconveyor system for advancing an item relative to a transport axis asdisclosed herein.

FIG. 5A is a perspective view of an exemplary drive module having asupport beam positioned outside the housing of the drive module forengagement with the housing, as disclosed herein. FIG. 5B is aperspective view of the exemplary drive module of FIG. 5A, showing thesupport beam secured to the housing of the drive module as disclosedherein.

FIG. 6A is a perspective view of the exemplary drive module of FIG. 5B,showing a carriage unit positioned outside the housing of the drivemodule for coupling with the support beam, as disclosed herein. FIG. 6Bis a perspective view of the exemplary drive module of FIG. 6A, showingthe carriage unit slidably coupled to the support beam as disclosedherein. FIG. 6C is an enlarged view of the boxed portion identified inFIG. 6B and shows the carriage unit engaging a mounting bracket of adrive pulley removal apparatus secured within the housing of the drivemodule as disclosed herein.

FIG. 7 is a perspective view of the exemplary drive module of FIGS.6B-6C, showing the drive pulley removal apparatus detached from thehousing of the drive module to remove a drive pulley from the housing asdisclosed herein.

FIG. 8A is a partially transparent side view of an exemplary take-upmodule that is positioned in a horizontal orientation. FIG. 8B is apartially transparent side view of the take-up module of FIG. 8A, withthe take-up module positioned in a tilted orientation (angled relativeto a horizontal axis) as disclosed herein. As shown, in eitherorientation of the take-up module, the weighted, gravity-based centertake-up pulley remains in a vertical orientation.

FIG. 9A is a side view of an exemplary drive module that is positionedin a horizontal orientation. FIG. 9B is a side view of the drive moduleof FIG. 9A, with the drive module positioned in a tilted orientation(angled relative to a horizontal axis) as disclosed herein. FIGS. 9A-9Balso depict a drive pulley removal apparatus positioned in engagementwith a drive pulley as disclosed herein. As shown, the drive pulleyremoval apparatus can be mounted to the drive module in a variety ofpositions to ensure that the drive pulley removal apparatus can achievea vertical orientation to permit removal of the drive pulley, regardlessof the orientation of the drive module.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout. It is tobe understood that this invention is not limited to the particularmethodology and protocols described, as such may vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to limit thescope of the present invention.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theinvention pertains having the benefit of the teachings presented in theforegoing description and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

As used herein the singular forms “a”, “an”, and “the” include pluralreferents unless the context clearly dictates otherwise. For example,use of the term “a drive module” can refer to one or more of such drivemodules unless the context indicates otherwise.

All technical and scientific terms used herein have the same meaning ascommonly understood to one of ordinary skill in the art to which thisinvention belongs unless clearly indicated otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list.

As used herein, the term “substantially,” when used to describe anangular orientation, refers to an angular orientation that is within upto 15 degrees (optionally, within 10 degrees, or within 5 degrees) ineither direction (positive or negative) of a referenced angularorientation. For example, if a component is provided “substantiallyparallel” to a reference surface, then the component can positioned atan angular orientation that is within up to 15 degrees (optionally,within 10 degrees, or within 5 degrees) of the angular orientation ofthe reference surface.

The following description supplies specific details in order to providea thorough understanding. Nevertheless, the skilled artisan wouldunderstand that the apparatus and associated methods of using theapparatus can be implemented and used without employing these specificdetails. Indeed, the apparatus, systems, and associated methods can beplaced into practice by modifying the illustrated apparatus, systems,and associated methods and can be used in conjunction with any otherapparatus, systems, and techniques conventionally used in the industry.

Disclosed herein, and with reference to FIGS. 1-9B, are conveyor systemsand methods of driving a conveyor to advance an item relative to atransport axis 12. In exemplary aspects, a conveyor drive assembly 20can be selectively positioned in a first configuration to define a firstconveyor movement pathway. As used herein, the term “conveyor movementpathway” refers to the overall shape, pattern, and direction of aconveyor belt passing through a conveyor system as disclosed herein.Optionally, the conveyor drive assembly 20 can comprise a plurality ofmodules, and each module of the conveyor drive assembly can have ahousing and a pulley assembly positioned within the housing. It iscontemplated that the housings of the plurality of modules can beselectively positioned relative to the transport axis 12 to define thefirst conveyor movement pathway. It is further contemplated that an itemplaced on a conveyor belt 14 engaged with the conveyor drive assembly 20can move relative to the first conveyor movement pathway. Optionally, itis further contemplated that the positioning of the housing of the atleast one module of the conveyor drive assembly 20 can be selectivelyadjusted to define a second conveyor movement pathway that is differentfrom the first conveyor movement pathway such that an item positioned onthe conveyor belt 14 can move relative to the second conveyor movementpathway. It is contemplated that the second conveyor movement pathwaycan differ from the first conveyor movement pathway in shape, pattern,direction, or combinations thereof. Non-limiting examples of suitableconveyor movement pathways are depicted in FIGS. 1-4.

Further disclosed herein, in various aspects and with reference to FIGS.1-7, are conveyor systems 10 for advancing an item relative to atransport axis 12. In various exemplary aspects, a conveyor system 10can comprise a conveyor belt 14 and a conveyor drive assembly 20, which,as further disclosed herein, can be a modular drive assembly. In theseexemplary aspects, the modular drive assembly 20 can comprise at leastone drive module 30 and at least one take-up module 60. Optionally, insome aspects, the disclosed drive assembly 20 can be non-reversing(i.e., configured to move in a single direction along a conveyormovement pathway). However, in other alternative aspects, it iscontemplated that the drive assembly 20 can be configured to bereversing (i.e., capable of changing its direction of movement along aconveyor movement pathway). In further aspects, each drive module 30 caninclude a housing 32 and a pulley assembly 36 that can be positionedwithin the housing 32. In these aspects, each pulley assembly 36 cancomprise a drive pulley 38 as further disclosed herein. It iscontemplated that each pulley assembly 36 can further comprise at leastone idler pulley (e.g., at least one “bend” pulley), such as, forexample and without limitation, first and second idler pulleys 39 a, 39b positioned on opposing sides of the drive pulley 38 relative to thetransport axis 12. In exemplary aspects and with reference to FIGS. 5A-7and 9A-9B, it is contemplated that the pulley assembly 36 of each drivemodule 30 can comprise a motorized drive pulley 38. It is contemplatedthat the motorized drive pulley 38 can comprise, for example and withoutlimitation, at least one drum motor.

Optionally, in further exemplary aspects, the components of the pulleyassembly 36 of each drive module 30 can be selectively rearranged orreplaced to accommodate various sizes of pulley assemblies and pulleyassembly components. It is contemplated that at least a portion of thepulley assembly 36 can be rearranged or replaced to accommodate variouschanges, such as changes in horsepower or speed. In these aspects, atleast a portion of the components of the pulley assembly 36 of eachdrive module 30 can be detachably secured within the housing 32 of thedrive module 30. In use, it is contemplated that at least one pulley(e.g., a drive pulley or idler pulley) of a pulley assembly 36 of adrive module 30 can be selectively removed and replaced by a secondpulley having a different size or different position than the pulley itis replacing. In exemplary aspects, it is contemplated that the drivepulley 38 of at least one of the pulley assemblies 36 can be selectivelyremoved and replaced by a second drive pulley to provide an adjustmentin speed or horsepower.

In another aspect, the pulley assembly 36 of each drive module 30 can beconfigured to engage the conveyor belt 14 and drive movement of theconveyor belt 14 along a conveyor movement pathway 42. In still furtheraspects, each take-up module 60 can include a housing 62 and a pulleyassembly 66 that can be positioned within the housing 62. In anotheraspect, the pulley assembly 66 of each take-up module 60 can beconfigured to engage the conveyor belt 14 and provide tension to theconveyor belt as the conveyor belt moves along the conveyor movementpathway 42. In these aspects, the respective positions of the housings32, 62 of the at least one drive module 30 and the at least one take-upmodule 60 relative to the transport axis 12 can be selectivelyadjustable to modify the conveyor movement pathway 42.

For example and without limitation, it is contemplated that thedisclosed conveyor systems 10 can be used on belt conveyors in eitherflat or incline/decline applications of up to about 15 degrees. Inexemplary aspects, the conveyor belt 14 can be oriented parallel orwithin about 1 degree (positive or negative) of parallel to a horizontalsurface, such as a floor, to achieve a flat configuration. In furtherexemplary aspects, at least a portion of the conveyor belt 14 can beoriented at an incline ranging from about 0 degrees to about 15 degrees,from about 0 degrees to about 5 degrees, from about 5 degrees to about10 degrees, or from about 10 degrees to about 15 degrees relative thehorizontal surface. Thus, in inclined configurations, it is contemplatedthat at least a portion of the conveyor belt 14 can be oriented at anincline of about 1 degree, about 2 degrees, about 3 degrees, about 4degrees, about 5 degrees, about 6 degrees, about 7 degrees, about 8degrees, about 9 degrees, about 10 degrees, about 11 degrees, about 12degrees, about 13 degrees, about 14 degrees, or about 15 degreesrelative to the horizontal surface. In further exemplary aspects, atleast a portion of the conveyor belt 14 can be oriented at a declineranging from about 0 degrees to about 15 degrees, from about 0 degreesto about 5 degrees, from about 5 degrees to about 10 degrees, or fromabout 10 degrees to about 15 degrees relative the horizontal surface.Thus, in declined configurations, it is contemplated that at least aportion of the conveyor belt 14 can be oriented at an decline of about 1degree, about 2 degrees, about 3 degrees, about 4 degrees, about 5degrees, about 6 degrees, about 7 degrees, about 8 degrees, about 9degrees, about 10 degrees, about 11 degrees, about 12 degrees, about 13degrees, about 14 degrees, or about 15 degrees relative to thehorizontal surface. Optionally, in exemplary aspects, it is contemplatedthat the conveyor movement pathway 42 can include a flat or horizontalportion and an inclined or declined portion. In still further optionalaspects, it is contemplated that the conveyor movement pathway 42 caninclude a flat or horizontal portion, an inclined portion, and adeclined portion.

In exemplary non-limiting aspects, in order to achieve a desiredconfiguration of the conveyor belt 14, it is contemplated that at leasta portion of the modular drive assembly 20 can be selectively positionedin a flat orientation, an inclined orientation, a declined orientation,or combinations thereof. In these aspects, it is contemplated that thehousing of each module 30, 60, 70, 80 of the entire modular driveassembly 20 can be selectively positioned (e.g., mounted) in anorientation needed to achieve a selected conveyor movement pathway asdisclosed herein. Thus, it is contemplated that the orientation ofselected modules of the modular drive assembly 20 themselves (ratherthan only portions of the conveyor belt) can be adjusted to achieve adesired pattern of the conveyor belt. In exemplary aspects, it iscontemplated that at least one module of the modular drive assembly 20can be positioned in an inclined orientation. When a take-up module ispositioned in an inclined position, it is contemplated that an adjacentdrive module can also be positioned in an inclined position to continuethe inclined path of the conveyor belt. Similarly, when a take-up moduleis positioned in a declined position, it is contemplated that anadjacent drive module can also be positioned in a declined position tocontinue the declined path of the conveyor belt. In further exemplaryaspects, it is contemplated that each module (take-up module 60, drivemodule 30, terminal module 70, upturn module 80) can be mounted in adesired orientation relative to the transport axis 12, such as, forexample, an inclined orientation, a horizontal/flat orientation, or adeclined orientation.

An exemplary modification of the angular orientation of a take-up module60 is depicted in FIGS. 8A-8B. As shown, the pulley assembly 66 cancomprise a center, gravity-based weighted pulley 67 and at least oneidler pulley (e.g., at least one “bend” pulley), such as, for exampleand without limitation, first and second idler pulleys 68 positioned onopposing sides of the center pulley 67 relative to the transport axis12. Optionally, the idler pulleys 68 of the pulley assembly 66 can bemounted to an upper portion of the housing 62. In exemplary aspects, thecenter pulley 67 can be coupled (e.g. secured) to a pair of guide armassemblies 69 that are pivotally coupled to the upper portion of housing62 at brackets/fulcrums 65. Optionally, in these aspects, the guide armassemblies 69 can have respective longitudinal axes and definerespective center openings 69 a that extend along the longitudinal axesand permit selective adjustment of the position of the center pulley 67relative to the longitudinal axes of the guide arm assemblies 69 (e.g.,with portions of the center pulley being configured for selectiveengagement with the guide arm assembly using conventional fasteners ormounting devices). As shown in FIG. 8A, when the take-up module 60 is ina flat or horizontal orientation, the guide arm assemblies 69 can bepositioned in a perpendicular or substantially perpendicular orientation(i.e., vertical or substantially vertical orientation) relative to thetransport axis 12. When the take-up module 60 is in an inclinedorientation (shown in FIG. 8B) or a declined orientation, the guide armassemblies 69 (and, thus, the center pulley 67) can be configured topivot relative to brackets/fulcrums 65 to maintain a vertical orsubstantially vertical orientation, which, in the inclined or declinedorientation, is angularly oriented relative to the transport axis 12(and the orientation of the conveyor belt 14). Thus, as the guide armassemblies 69 pivot, the center-to-center distances between the centerpulley 67 and the idler pulleys 68 can vary (increase or decrease),depending on the direction of pivotal movement.

An exemplary modification of the angular orientation of a drive module30 is depicted in FIGS. 9A-9B. In exemplary aspects, the first andsecond idler pulleys 39 a, 39 b of the pulley assembly 36 can be mountedto an upper portion of the housing 32. Optionally, in these aspects, thefirst idler pulley 39 a can be larger than the second idler pulley 39 b.As shown in FIGS. 5A-6C and 9A-9B, the drive module 30 can comprise aside support frame 56 that extends horizontally across the module and isconfigured to support the drive pulley 38 in a central (or otherdesired) position relative to the transport axis 12. It is contemplatedthat the side support frame 56 can be selectively replaced depending onthe particular size of a particular drive module 30 or drive pulley 38.In order to modify the angular orientation of the conveyor belt 14through the drive module 30, the housing 32 of the drive module can bemounted at a selected incline or decline. However, unlike the take-upmodule, the inner components of the drive module 30 do not pivotrelative to the housing 32, and the relative positions of the pulleys38, 39 a, 39 b within the drive module, and the orientations of thepulleys with respect to the conveyor belt 14 and the transport axis,remain unchanged, regardless of the angular orientation of the drivemodule.

In exemplary aspects, the at least one drive module 30 can comprise asingle drive module. Optionally, however, it is contemplated that the atleast one drive module 30 can comprise a plurality of drive modules. Infurther aspects, the at least one take-up module 60 can comprise asingle take-up module. Alternatively, in optional aspects, it iscontemplated that the at least one take-up module 60 can comprise aplurality of take-up modules. In one exemplary aspect, it iscontemplated that the at least one drive module 30 can comprise a singledrive module and that the at least one take-up module 60 can comprise asingle take-up module. In another exemplary aspect, it is contemplatedthat the at least one drive module 30 can comprise a plurality of drivemodules and that the at least one take-up module 60 can comprise aplurality of take-up modules.

In exemplary aspects, the housing 32 of a first drive module 30 of theat least one drive module 30 can be positioned adjacent the housing 62of a first take-up module 60 of the at least one take-up module 60. Infurther exemplary aspects, the housings 32, 62 of the first drive module30 and the first take-up module 60 can define respective openings 34, 64that receive portions of the conveyor belt 14 that extend between thepulley assembly 36 of the first drive module 30 and the pulley assembly66 of the first take-up module 60.

In further exemplary aspects, the conveyor movement pathway 42 can haveopposing input and output ends 44, 46 that can be spaced apart relativeto the transport axis 12. As shown in FIGS. 2 and 3, the drive assembly20 of the conveyor system 10 can further comprise at least one terminalmodule 70. In these aspects, each terminal module 70 can have a housing72 and a pulley 76 positioned within the housing 72. It is contemplatedthat the pulley 76 of each terminal module 70 can be configured toengage the conveyor belt 14.

In some exemplary aspects, a terminal module 70 can be positioned at theinput end 44 of the conveyor movement pathway 42. Additionally, oralternatively, in other aspects, a terminal module 70 can be positionedat the output end 46 of the conveyor movement pathway 42. In theseaspects, it is contemplated that the housing 72 of each terminal module70 can be selectively connectable to the housing 32 of a drive module 30or a take-up module 60 of the modular drive assembly 20.

Optionally, in one exemplary aspect and with reference to FIG. 2, the atleast one terminal module 70 can comprise a first terminal module 70. Inthis aspect, the housing 72 of the first terminal module 70 can beconnected to the housing 32 of a drive module 30 of the modular driveassembly 20. In a further aspect, the housing 72 of the first terminalmodule 70 can define at least one opening 74 that can receive portionsof the conveyor belt 14 that extend between the pulley 76 of the firstterminal module 70 and the pulley assembly 36 of the drive module 30 towhich the first terminal module 70 can be connected. In still a furtheraspect, the first terminal module 70 can be positioned at the output end46 of the conveyor movement pathway 42. In another aspect, as shown inFIG. 2, the pulley 76 of the first terminal module 70 can direct adownturn of the conveyor belt 14.

Optionally, in another aspect and with reference to FIG. 3, the at leastone terminal module 70 can comprise a first terminal module 70. In thisaspect, the housing 72 of the first terminal module 70 can be connectedto the housing 62 of a take-up module 60 of the modular drive assembly20. In a further aspect, the housing 72 of the first terminal module 70can define at least one opening 74 that can receive portions of theconveyor belt 14 that extend between the pulley 76 of the first terminalmodule 70 and the pulley assembly 66 of the take-up module 60 to whichthe first terminal module 70 can be connected. In still a furtheraspect, the first terminal module 70 can be positioned at the input end44 of the conveyor movement pathway 42. In another aspect, as shown inFIG. 3, the pulley 76 of the first terminal module 70 can direct anupturn of the conveyor belt 14.

In other exemplary aspects and with reference to FIG. 4, it iscontemplated that the conveyor system 10 can further comprise an upturnmodule 80. In these aspects, the upturn module 80 can comprise a housing82 and first and second pulleys 84, 86 positioned within the housing 82.In further aspects, the housing 82 of the upturn module 80 can bepositioned beneath the housings 62, 32 of the first take-up module 60and the first drive module 30. In still further aspects, the firstpulley 84 of the upturn module 80 can be configured to direct theconveyor belt 14 toward the pulley assembly 36 of the first drive module30. In a further aspect, the pulley assembly 36 of the first drivemodule 30 can be configured to direct the conveyor belt 14 toward thepulley assembly 66 of the first take-up module 60. In another aspect,the pulley assembly 66 of the first take-up module 60 can be configuredto direct the conveyor belt 14 toward the second pulley 86 of the upturnmodule 80. In these aspects, as shown in FIG. 4, it is contemplated thatthe first and second pulleys 84, 86 of the upturn module 80 and thepulley assemblies 66, 36 of the first take-up module 60 and the firstdrive module 30 can cooperate to effect an upturn of the conveyor belt14.

In a further aspect, the housing 82 of the upturn module 80 can defineat least one opening 88 that can receive portions of the conveyor belt14 that extend (a) between the first pulley 84 of the upturn module 80and the pulley assembly 36 of the drive module 30 to which the upturnmodule 80 can be connected or (b) between the pulley assembly 66 of thetake-up module 60 to which the upturn module 80 can be connected and thesecond pulley 86 of the upturn module. In this aspect, it is furthercontemplated that the drive module 30 and the take-up module 60 cancomprise openings 34, 64 that are positioned in alignment withrespective openings 88 of the upturn module 80 and configured to receivecorresponding portions of the conveyor belt 14.

In exemplary aspects, it is contemplated that each of the modules 30,60, 70, 80 disclosed herein can have respective side covers that can beselectively removed to provide access to the pulleys and othercomponents within each module. Optionally, in these aspects, it iscontemplated that each module can have two side covers that are spacedapart relative to an axis that is perpendicular or substantiallyperpendicular to the transport axis 12. In further exemplary aspects, itis contemplated that each module can have fixed support walls extendingbetween the side covers, with the fixed support walls optionallydefining openings as disclosed herein.

In further exemplary aspects, the motorized drive pulley 38 of eachdrive module 30 can be selectively removable and replaceable. In theseaspects, each drive module 30 can comprise a drive pulley removalapparatus 48 that can be detachably secured within the housing 32 of thedrive module 30. In these aspects, the drive pulley removal apparatus 48can facilitate the removal and replacement of the motorized drive pulley38 without needing to “break” the conveyor belt 14, as further describedherein.

In another aspect, as shown in FIGS. 6B-6C, the motorized drive pulley38 of each drive module 30 can comprise at least one mounting bracket 40for detachably securing the motorized drive pulley 38 to the housing 32of the drive module 30. Following detachment of the motorized drivepulley 38 from the housing 32 of the drive module 30, the drive pulleyremoval apparatus 48 can be configured to engage the at least onemounting bracket 40 of the motorized drive pulley 38 and effect movementof the motorized drive pulley 38 from a stowed position within thehousing 32 of the drive module 30 to an accessible position in which atleast a portion of the motorized drive pulley 38 is outside the housing32 of the drive module 30, as shown in FIG. 7. It is contemplated thatthe mounting bracket 40 can serve as a lifting lug for lifting the drivepulley 38 using the drive pulley removal apparatus 48. It is furthercontemplated that the mounting brackets 40 can provide consistentlocations within the module 30 for establishing engagement between thedrive pulley removal apparatus 48 and the drive pulley 38. Optionally,in exemplary aspects, it is contemplated that the drive pulley cancomprise two opposed mounting brackets (positioned on opposite ends ofthe drive pulley) that are configured to engage corresponding portionsof the drive pulley removal apparatus 48.

In still further exemplary aspects, as shown in FIGS. 5A-6C, the drivepulley removal apparatus 48 of each drive module 30 can comprise asupport beam 50 that can be secured to the housing 32 of the drivemodule 30. In further exemplary aspects, the drive pulley removalapparatus 48 of each drive module 30 can comprise a carriage unit 52that can be configured to engage the at least one mounting bracket 40 ofthe motorized drive pulley 38. In these aspects, as shown in FIGS.6A-6C, the carriage unit 52 can be slidably coupled to the support beam50 to permit axial translation of the carriage unit 52 relative to thesupport beam 50. In further aspects, as shown in FIG. 6C, the carriageunit 52 can comprise at least one fastener or adjustable linkage (e.g.,lifting device or turnbuckle 54), and each fastener or adjustablelinkage (e.g., lifting device or turnbuckle 54) can be configured toengage and permit lifting of a respective mounting bracket 40 of themotorized drive pulley 38 of the drive module 30. Optionally, inexemplary aspects, the at least one fastener or adjustable linkage cancomprise opposed fasteners or adjustable linkages that are positioned onopposing ends of the support beam 50 and configured to engagecorresponding opposed mounting brackets 40 of the drive pulley 38.

As further described herein, in exemplary aspects, the drive module 30for the conveyor system 10 can comprise a housing 32, a pulley assembly36, and a drive pulley removal apparatus 48. In these aspects, thepulley assembly 36 can be positioned within the housing 32 and cancomprise a motorized drive pulley 38. In further aspects, the motorizeddrive pulley 38 can comprise at least one mounting bracket 40 fordetachably securing the motorized drive pulley 38 to the housing 32. Instill further aspects, the motorized drive pulley 38 of each drivemodule 30 can be selectively removable and replaceable. In theseaspects, the drive pulley removal apparatus 48 can be detachably securedwithin the housing 32. Following detachment of the motorized drivepulley 38 from the housing 32, it is contemplated that the drive pulleyremoval apparatus 48 can be configured to engage the at least onemounting bracket 40 of the motorized drive pulley 38 and effect movementof the motorized drive pulley 38 from a stowed position within thehousing 32 of the drive module 30 to an accessible position in which atleast a portion of the motorized drive pulley 38 is outside the housing32 of the drive module 30. As shown in FIGS. 5A-6C, movement of thedrive pulley 38 from the stowed position to the accessible position canoccur relative to a movement pathway that is perpendicular orsubstantially perpendicular to the transport axis 12. In furtheraspects, the drive pulley removal apparatus 48 can comprise a supportbeam 50 that can be secured to the housing 32 of the drive module 30. Infurther aspects, the drive pulley removal apparatus 48 can comprise acarriage unit 52 that can be configured to engage the at least onemounting bracket 40 of the motorized drive pulley 38. In these aspects,the carriage unit 52 can be slidably coupled to the support beam 50 topermit axial translation of carriage unit 52 relative to the supportbeam 50 (for example, relative to an axis that is perpendicular orsubstantially perpendicular to the transport axis 12).

To assemble the drive pulley removal apparatus 48 to the drive module30, the side covers for the drive module 30 can be removed to expose theinner components as disclosed herein. Then, the support beam 50 can beplaced inside the drive module 30 and bolted to mounting points 35, asshown in FIGS. 5A-5B. Subsequently, the carriage unit 52 can be insertedonto the support beam 50 and the turnbuckle attachments 54 can beconnected to the mounting brackets 40 of the motorized drive pulley 38,as shown in FIGS. 6A-6C. Once the turnbuckles 54 are tightened and themounting bracket 40 is unbolted from a side support frame 56, the sidesupport frame can be removed from the drive module 30 to provide openaccess to the motorized drive pulley 38. With the motorized drive pulley38 suspended freely by the carriage unit 52 and fasteners (e.g.,turnbuckles 54), the motorized drive pulley 38 can be laterally movedout of the drive module 30 from the stowed position to the accessibleposition, as shown in FIG. 7. From this position, the motorized drivepulley 38 can be easily accessed by external devices needed to supportthe drive pulley, such as, for example and without limitation, riggingdevices. As would be appreciated by one of skill in the art, the processcan be reversed for re-installation purposes.

As shown in FIGS. 9A-9B, the housing 32 of each drive module 30 candefine a plurality of mounting points 35 in an upper portion of thehousing to permit mounting of the drive pulley removal apparatus 48 tothe housing 32 in an orientation (e.g., a vertical orientation) thatpermits engagement between the drive pulley removal apparatus 48 and themounting brackets 40 of the motorized drive pulley 38. For example, whenthe drive module 30 is positioned in a flat or horizontal orientation asshown in FIG. 9A, the drive pulley removal apparatus 48 can be mountedto the housing at a first mounting point 35 (e.g. a center mountingpoint) that is positioned in vertical alignment with the at least onemounting bracket 40. When the drive module 30 is positioned in aninclined orientation as shown in FIG. 9B, the drive pulley removalapparatus 48 can be mounted to the housing at a second mounting point 35different from the first mounting point that is positioned in verticalalignment with the at least one mounting bracket 40 with the module inthe inclined orientation. Thus, in any configuration of the module, thedrive pulley removal apparatus 48 can achieve a vertical orientationthat permits removal of the drive pulley 38.

In use, it is contemplated that a conveyor drive assembly, or moreparticularly a modular drive assembly 20, can be selectively positionedin a first configuration to define a first conveyor movement pathway.The conveyor drive assembly 20 can comprise a plurality of modules 30,60, 70, 80, with each module of the conveyor drive assembly 20 having ahousing and a pulley assembly that can be positioned within the housing.The housings of the plurality of modules can be selectively positionedrelative to the transport axis 12 to define the first conveyor movementpathway. A first item can be positioned on a conveyor belt 14 that ispositioned in engagement with the pulley assembly of each module of theconveyor drive assembly 20. It is contemplated that the movement of theconveyor belt 14 can be driven relative to the first conveyor movementpathway. If desired, the conveyor belt 14 can be disengaged from thepulley assembly of at least one module of the conveyor drive assembly20. Optionally, the position or orientation of the housing of at leastone module of the conveyor drive assembly 20 can be selectively adjustedto define a second conveyor movement pathway that can be different fromthe first conveyor movement pathway (for example, different in shape,pattern, direction, angular orientation, or combinations thereof). Oncethe housing is positioned as desired, the conveyor belt 14 can befurther positioned in engagement with the pulley assemblies of theplurality of modules of the conveyor drive assembly 20. A second itemcan be positioned on the conveyor belt 14, and movement of the conveyorbelt 14 can be driven relative to the second conveyor movement pathway.

In exemplary aspects, it is contemplated that the plurality of modulescan comprise a drive module 30, and the pulley assembly 36 of the drivemodule 30 can comprise a motorized drive pulley 38. In use, a conveyordrive assembly 20 can be positioned in a first configuration to definethe first conveyor movement pathway, as described herein. The housingsof the plurality of modules can be selectively positioned relative tothe transport axis 12 to define the first conveyor movement pathway.Optionally, a conveyor belt 14 can be positioned in engagement with thepulley assemblies of the plurality of modules of the conveyor driveassembly 20 such that the conveyor belt 14 forms a closed loop. It iscontemplated that the motorized drive pulley 38 of the drive module 30can be selectively removed and replaced without breaking the closed loopformed by the conveyor belt 14. In further exemplary aspects, the drivemodule 30 can comprise a drive pulley removal apparatus 48 that can bedetachably secured within the housing 32 of the drive module 30. Inthese aspects, the motorized drive pulley 38 can be selectively removedand replaced by detaching the motorized drive pulley 38 from the housing32, engaging the motorized drive pulley 38 with a drive pulley removalapparatus 48 secured to the housing 32 of the drive module 30, and usingthe drive pulley removal apparatus 48 to move the motorized drive pulley38 from a stowed position within the housing 32 of the drive module 30to an accessible position in which at least a portion of the motorizeddrive pulley 38 is outside the housing 32 of the drive module 30.

It is contemplated that certain implementations of the systems andmethods disclosed herein can provide one or more advantages. Forexample, at least four basic drive configurations can be produced fromthe disclosed modules, which can provide benefits throughstandardization of parts, simplification of the conveyor system designprocess, and production cost benefits. The modular conveyor systemdisclosed herein can also provide flexible conveyor configurations andallow easy reuse if conveyors are dismantled or reconfigured. It isfurther contemplated that the disclosed systems and methods can allowfor conveyor drive horsepower or speed changes to be made without havingto make major modifications to the drive module because, for example andwithout limitation, it is possible to only replace the motorized drivepulley 38 and its mounting brackets 40. It is further contemplated thatthe disclosed systems and methods can allow for the maximum benefitsfrom a motorized drive pulley 38 to be realized, including, for exampleand without limitation: a compact design; full-enclosure of the modulesto prevent debris from entering the modules and to dampen the noiseoutput levels; low maintenance through elimination of common points offailure such as drive belts (e.g., HTD Belts), drive chains, andMotor/Reducer Couplings; and increased safety as compared to aconventional drive due to the elimination of internal drive modulecomponents that require maintenance personnel to be inside the drivemodule 30 to adjust. As further described herein, it is alsocontemplated that the drive pulley removal apparatus 48 can simplify thetask of installing and removing a motorized drive pulley 38, which helpsto reduce maintenance downtime.

Exemplary Aspects

In view of the described devices, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspect 1: A conveyor system for advancing an item relative to atransport axis, the conveyor system comprising: a conveyor belt; and amodular drive assembly comprising: at least one drive module, each drivemodule having a housing and a pulley assembly positioned within thehousing, wherein the pulley assembly of each drive module is configuredto engage the conveyor belt and drive movement of the conveyor beltalong a conveyor movement pathway; and at least one take-up module, eachtake-up module having a housing and a pulley assembly positioned withinthe housing, wherein the pulley assembly of each take-up module isconfigured to engage the conveyor belt and provide tension to theconveyor belt as the conveyor belt moves along the conveyor movementpathway, wherein respective positions of the housings of the at leastone drive module and the at least one take-up module relative to thetransport axis are selectively adjustable to modify the conveyormovement pathway.

Aspect 2: The conveyor system of aspect 1, wherein the at least onedrive module comprises a single drive module.

Aspect 3: The conveyor system of aspect 1 or aspect 2, wherein the atleast one take-up module comprises a single take-up module.

Aspect 4: The conveyor system of any one of the preceding aspects,wherein the housing of a first drive module of the at least one drivemodule is positioned adjacent the housing of a first take-up module ofthe at least one take-up module, and wherein the housings of the firstdrive module and the first take-up module define respective openingsthat receive portions of the conveyor belt that extend between thepulley assembly of the first drive module and the pulley assembly of thefirst take-up module.

Aspect 5: The conveyor system of any one of the preceding aspects,wherein the conveyor movement pathway has opposing input and output endsthat are spaced apart relative to the transport axis, wherein the driveassembly of the conveyor system further comprises at least one terminalmodule, each terminal module having a housing and a pulley positionedwithin the housing, wherein the pulley of each terminal module isconfigured to engage the conveyor belt, wherein each terminal module ispositioned at either the input end or the output end of the conveyormovement pathway, and wherein the housing of each terminal module isselectively connectable to the housing of a drive module or a take-upmodule of the modular drive assembly.

Aspect 6: The conveyor system of aspect 5, wherein the at least oneterminal module comprises a first terminal module, wherein the housingof the first terminal module is connected to the housing of a drivemodule of the modular drive assembly, and wherein the housing of thefirst terminal module defines at least one opening that receivesportions of the conveyor belt that extend between the pulley of thefirst terminal module and the pulley assembly of the drive module towhich the first terminal module is connected.

Aspect 7: The conveyor system of aspect 6, wherein the first terminalmodule is positioned at the output end of the conveyor movement pathway.

Aspect 8: The conveyor system of aspect 7, wherein the pulley of thefirst terminal module directs a downturn of the conveyor belt.

Aspect 9: The conveyor system of any one of aspects 1-8, wherein the atleast one terminal module comprises a first terminal module, wherein thehousing of the first terminal module is connected to the housing of atake-up module of the modular drive assembly, and wherein the housing ofthe first terminal module defines at least one opening that receivesportions of the conveyor belt that extend between the pulley of thefirst terminal module and the pulley assembly of the take-up module towhich the first terminal module is connected.

Aspect 10: The conveyor system of aspect 9, wherein the first terminalmodule is positioned at the input end of the conveyor movement pathway.

Aspect 11: The conveyor system of aspect 10, wherein the pulley of thefirst terminal module directs an upturn of the conveyor belt.

Aspect 12: The conveyor system of any one of aspects 4-11, furthercomprising an upturn module having a housing and first and secondpulleys positioned within the housing, wherein the housing of the upturnmodule is positioned beneath the housings of the first take-up moduleand the first drive module, wherein the first pulley of the upturnmodule is configured to direct the conveyor belt toward the pulleyassembly of the first drive module, wherein the pulley assembly of thefirst drive module is configured to direct the conveyor belt toward thepulley assembly of the first take-up module, wherein the pulley assemblyof the first take-up module is configured to direct the conveyor belttoward the second pulley of the upturn module, and wherein the first andsecond pulleys of the upturn module and the pulley assemblies of thefirst take-up module and the first drive module cooperate to effect anupturn of the conveyor belt.

Aspect 13: The conveyor system of any of the preceding aspects, whereinthe pulley assembly of each drive module comprises a motorized drivepulley.

Aspect 14: The conveyor system of aspect 13, wherein the motorized drivepulley of each drive module is selectively removable and replaceable.

Aspect 15: The conveyor system of aspect 14, wherein each drive modulecomprises a drive pulley removal apparatus detachably secured within thehousing of the drive module.

Aspect 16: The conveyor system of aspect 15, wherein the motorized drivepulley of each drive module comprises at least one mounting bracket fordetachably securing the motorized drive pulley to the housing of thedrive module, and wherein, following detachment of motorized drivepulley from the housing of the drive module, the drive pulley removalapparatus is configured to engage the at least one mounting bracket ofthe motorized drive pulley and effect movement of the motorized drivepulley from a stowed position within the housing of the drive module toan accessible position in which at least a portion of the motorizeddrive pulley is outside the housing of the drive module.

Aspect 17: The conveyor system of aspect 16, wherein the drive pulleyremoval apparatus of each drive module comprises: a support beam securedto the housing of the drive module; and a carriage unit configured toengage the at least one mounting bracket of the motorized drive pulley,wherein the carriage unit is slidably coupled to the support beam topermit axial translation of carriage unit relative to the support beam.

Aspect 18: The conveyor system of aspect 17, wherein the carriage unitcomprises at least one turnbuckle, wherein each turnbuckle is configuredto engage a respective mounting bracket of the motorized drive pulley ofthe drive module.

Aspect 19: A drive module for a conveyor system, the drive modulecomprising: a housing; a pulley assembly positioned within the housingand comprising a motorized drive pulley, the motorized drive pulleycomprising at least one mounting bracket for detachably securing themotorized drive pulley to the housing, wherein the motorized drivepulley of each drive module is selectively removable and replaceable;and a drive pulley removal apparatus detachably secured within thehousing, wherein, following detachment of motorized drive pulley fromthe housing, the drive pulley removal apparatus is configured to engagethe at least one mounting bracket of the motorized drive pulley andeffect movement of the motorized drive pulley from a stowed positionwithin the housing of the drive module to an accessible position inwhich at least a portion of the motorized drive pulley is outside thehousing of the drive module.

Aspect 20: The drive module of aspect 19, wherein the drive pulleyremoval apparatus comprises: a support beam secured to the housing ofthe drive module; and a carriage unit configured to engage the at leastone mounting bracket of the motorized drive pulley, wherein the carriageunit is slidably coupled to the support beam to permit axial translationof carriage unit relative to the support beam.

Aspect 21: A method of driving a conveyor to advance an item relative toa transport axis, the method comprising: selectively positioning aconveyor drive assembly in a first configuration to define a firstconveyor movement pathway, wherein the conveyor drive assembly comprisesa plurality of modules, each module of the conveyor drive assemblyhaving a housing and a pulley assembly positioned within the housing,and wherein the housings of the plurality of modules are selectivelypositioned relative to the transport axis to define the first conveyormovement pathway; positioning a first item on a conveyor belt positionedin engagement with the pulley assembly of each module of the conveyordrive assembly; driving movement of the conveyor belt relative to thefirst conveyor movement pathway; disengaging the conveyor belt from thepulley assembly of at least one module of the conveyor drive assembly;selectively adjusting the positioning of the housing of at least onemodule of the conveyor drive assembly to define a second conveyormovement pathway that is different from the first conveyor movementpathway; positioning the conveyor belt in engagement with the pulleyassemblies of the plurality of modules of the conveyor drive assembly;positioning a second item on the conveyor belt; and driving movement ofthe conveyor belt relative to the second conveyor movement pathway.

Aspect 22: A method of driving a conveyor to advance an item relative toa transport axis, the method comprising: selectively positioning aconveyor drive assembly in a first configuration to define a firstconveyor movement pathway, wherein the conveyor drive assembly comprisesa plurality of modules, each module of the conveyor drive assemblyhaving a housing and a pulley assembly positioned within the housing,wherein the plurality of modules comprises a drive module, wherein thepulley assembly of the drive module comprises a motorized drive pulley,wherein the housings of the plurality of modules are selectivelypositioned relative to the transport axis to define the first conveyormovement pathway; positioning a conveyor belt in engagement with thepulley assemblies of the plurality of modules of the conveyor driveassembly such that the conveyor belt forms a closed loop; andselectively removing and replacing the motorized drive pulley of thedrive module without breaking the closed loop formed by the conveyorbelt.

Aspect 23: The method of aspect 22, wherein the drive module comprises adrive pulley removal apparatus detachably secured within the housing ofthe drive module, and wherein selectively removing and replacing themotorized drive pulley comprises: detaching the motorized drive pulleyfrom the housing; engaging the motorized drive pulley with a drivepulley removal apparatus secured to the housing of the drive module; andusing the drive pulley removal apparatus to move the motorized drivepulley from a stowed position within the housing of the drive module toan accessible position in which at least a portion of the motorizeddrive pulley is outside the housing of the drive module.

All publications and patent applications mentioned in the specificationare indicative of the level of those skilled in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated to be incorporated by reference.

Although the foregoing invention has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, certain changes and modifications may be practiced withinthe scope of the appended claims.

What is claimed is:
 1. A conveyor system for advancing an item relativeto a transport axis, the conveyor system comprising: a conveyor belt;and a modular drive assembly comprising: at least one drive module, eachdrive module having a housing and a pulley assembly positioned withinthe housing, wherein the pulley assembly of each drive module isconfigured to engage the conveyor belt and drive movement of theconveyor belt along a conveyor movement pathway; and at least onetake-up module, each take-up module having a housing and a pulleyassembly positioned within the housing, wherein the pulley assembly ofeach take-up module is configured to engage the conveyor belt andprovide tension to the conveyor belt as the conveyor belt moves alongthe conveyor movement pathway, wherein respective positions of thehousings of the at least one drive module and the at least one take-upmodule relative to the transport axis are selectively adjustable tomodify the conveyor movement pathway.
 2. The conveyor system of claim 1,wherein the at least one drive module comprises a single drive module.3. The conveyor system of claim 1, wherein the at least one take-upmodule comprises a single take-up module.
 4. The conveyor system ofclaim 1, wherein the housing of a first drive module of the at least onedrive module is positioned adjacent the housing of a first take-upmodule of the at least one take-up module, and wherein the housings ofthe first drive module and the first take-up module define respectiveopenings that receive portions of the conveyor belt that extend betweenthe pulley assembly of the first drive module and the pulley assembly ofthe first take-up module.
 5. The conveyor system of claim 4, furthercomprising an upturn module having a housing and first and secondpulleys positioned within the housing, wherein the housing of the upturnmodule is positioned beneath the housings of the first take-up moduleand the first drive module, wherein the first pulley of the upturnmodule is configured to direct the conveyor belt toward the pulleyassembly of the first drive module, wherein the pulley assembly of thefirst drive module is configured to direct the conveyor belt toward thepulley assembly of the first take-up module, wherein the pulley assemblyof the first take-up module is configured to direct the conveyor belttoward the second pulley of the upturn module, and wherein the first andsecond pulleys of the upturn module and the pulley assemblies of thefirst take-up module and the first drive module cooperate to effect anupturn of the conveyor belt.
 6. The conveyor system of claim 1, whereinthe conveyor movement pathway has opposing input and output ends thatare spaced apart relative to the transport axis, wherein the driveassembly of the conveyor system further comprises at least one terminalmodule, each terminal module having a housing and a pulley positionedwithin the housing, wherein the pulley of each terminal module isconfigured to engage the conveyor belt, wherein each terminal module ispositioned at either the input end or the output end of the conveyormovement pathway, and wherein the housing of each terminal module isselectively connectable to the housing of a drive module or a take-upmodule of the modular drive assembly.
 7. The conveyor system of claim 6,wherein the at least one terminal module comprises a first terminalmodule, wherein the housing of the first terminal module is connected tothe housing of a drive module of the modular drive assembly, and whereinthe housing of the first terminal module defines at least one openingthat receives portions of the conveyor belt that extend between thepulley of the first terminal module and the pulley assembly of the drivemodule to which the first terminal module is connected.
 8. The conveyorsystem of claim 7, wherein the first terminal module is positioned atthe output end of the conveyor movement pathway.
 9. The conveyor systemof claim 8, wherein the pulley of the first terminal module directs adownturn of the conveyor belt.
 10. The conveyor system of claim 6,wherein the at least one terminal module comprises a first terminalmodule, wherein the housing of the first terminal module is connected tothe housing of a take-up module of the modular drive assembly, andwherein the housing of the first terminal module defines at least oneopening that receives portions of the conveyor belt that extend betweenthe pulley of the first terminal module and the pulley assembly of thetake-up module to which the first terminal module is connected.
 11. Theconveyor system of claim 10, wherein the first terminal module ispositioned at the input end of the conveyor movement pathway.
 12. Theconveyor system of claim 11, wherein the pulley of the first terminalmodule directs an upturn of the conveyor belt.
 13. The conveyor systemof claim 1, wherein the pulley assembly of each drive module comprises amotorized drive pulley.
 14. The conveyor system of claim 13, wherein themotorized drive pulley of each drive module is selectively removable andreplaceable.
 15. The conveyor system of claim 14, wherein each drivemodule comprises a drive pulley removal apparatus detachably securedwithin the housing of the drive module.
 16. The conveyor system of claim15, wherein the motorized drive pulley of each drive module comprises atleast one mounting bracket for detachably securing the motorized drivepulley to the housing of the drive module, and wherein, followingdetachment of motorized drive pulley from the housing of the drivemodule, the drive pulley removal apparatus is configured to engage theat least one mounting bracket of the motorized drive pulley and effectmovement of the motorized drive pulley from a stowed position within thehousing of the drive module to an accessible position in which at leasta portion of the motorized drive pulley is outside the housing of thedrive module.
 17. The conveyor system of claim 16, wherein the drivepulley removal apparatus of each drive module comprises: a support beamsecured to the housing of the drive module; and a carriage unitconfigured to engage the at least one mounting bracket of the motorizeddrive pulley, wherein the carriage unit is slidably coupled to thesupport beam to permit axial translation of the carriage unit relativeto the support beam.
 18. The conveyor system of claim 17, wherein thecarriage unit comprises at least one turnbuckle, wherein each turnbuckleis configured to engage a respective mounting bracket of the motorizeddrive pulley of the drive module.